Download BRAKE SYSTEM SECTION BR

BRAKE SYSTEM
SECTION
BR
CONTENTS
PRECAUTIONS AND PREPARATION............................3
Supplement Restraint System (SRS) ″AIR BAG″
and ″SEAT BELT PRE-TENSIONER″ .........................3
Precautions ..................................................................3
Preparation ..................................................................4
CHECK AND ADJUSTMENT ..........................................5
Checking Brake Fluid Level.........................................5
Checking Brake Line ...................................................5
Changing Brake Fluid ..................................................5
Brake Burnishing Procedure........................................5
BRAKE HYDRAULIC LINE .............................................6
Bleeding Brake System ...............................................8
Removal.......................................................................9
Inspection.....................................................................9
Installation....................................................................9
LOAD SENSING VALVE ...............................................10
Removal and Installation ...........................................10
Removal.....................................................................11
Installation..................................................................11
Inspection and Adjustment ........................................12
BRAKE PEDAL AND BRACKET..................................14
Removal and Installation ...........................................14
Inspection...................................................................15
Adjustment .................................................................15
MASTER CYLINDER.....................................................16
Removal.....................................................................16
Installation..................................................................16
BRAKE BOOSTER........................................................17
Removal and Installation ...........................................17
Inspection...................................................................17
Installation..................................................................18
VACUUM HOSE.............................................................19
Removal and Installation ...........................................19
Inspection...................................................................21
VACUUM PUMP (TD27Ti engine model) ....................23
Removal and Installation ...........................................23
Inspection...................................................................23
VACUUM PUMP (ZD30DDTi engine model) ...............25
Removal and Installation ...........................................25
FRONT DISC BRAKE ...................................................26
Pad Replacement ......................................................26
Removal.....................................................................27
Disassembly...............................................................27
Inspection...................................................................27
Assembly ...................................................................28
Inspection...................................................................28
Installation..................................................................30
REAR DRUM BRAKE ...................................................31
Removal.....................................................................32
Shoe Replacement ....................................................33
Inspection...................................................................33
Installation..................................................................33
PARKING BRAKE CONTROL ......................................35
Removal and Installation ...........................................35
Inspection...................................................................35
Adjustment .................................................................35
ANTI-LOCK BRAKE SYSTEM......................................37
Purpose......................................................................37
Operation ...................................................................37
ABS Hydraulic Circuit ................................................37
System Description....................................................38
Removal and Installation ...........................................42
TROUBLE DIAGNOSES ...............................................47
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................47
Component Parts and Harness Connector
Location .....................................................................48
Circuit Diagram for Quick Pinpoint Check.................49
Wiring Diagram - ABS - .............................................50
CONSULT-II ...............................................................58
CONSULT-II Inspection Procedure............................59
Preliminary Check......................................................65
Ground Circuit Check ................................................66
Diagnostic Procedure 1 (Not self-diagnostic item)....67
CONTENTS
Diagnostic Procedure 2 (Warning lamp stays on
when ignition switch is turned ON)............................69
Diagnostic Procedure 3 (ABS actuator solenoid
valve and solenoid valve relay) .................................71
Diagnostic Procedure 4 (Wheel sensor or rotor) ......73
Diagnostic Procedure 5 (Motor Relay or motor) .......75
Diagnostic Procedure 7 (Low voltage) ......................77
Diagnostic Procedure 8 (G sensor)...........................78
Diagnostic Procedure 9 (Control unit) .......................79
Diagnostic Procedure 10 (Pedal vibration and
noise) .........................................................................80
(Cont’d)
Diagnostic Procedure 11 (Long stopping
distance) ....................................................................80
Diagnostic Procedure 12 (Unexpected pedal
action) ........................................................................81
Diagnostic Procedure 13 ...........................................82
Diagnostic Procedure 14 ...........................................82
Electrical Components Inspection .............................83
SERVICE DATA AND SPECIFICATIONS (SDS) ..........84
General Specifications...............................................84
Inspection and Adjustment ........................................85
BR-2
PRECAUTIONS AND PREPARATION
Supplement Restraint System (SRS) “AIR BAG”
and “SEAT BELT PRE-TENSIONER”
The Supplemental Restraint System “Air Bag” and “Seat Belt Pre-tensioner”, used along with a seat belt, help
to reduce the risk or severity or injury to the driver and front passenger in a collision. The Supplemental
Restraint System consists of an air bag module (located in the center of the steering wheel and on the instrument panel on the passenger side, where fitted), seat belt pre-tensioners, a diagnosis sensor unit, warning
lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the
BT section of this Service Manual.
WARNING:
I To avoid rendering the SRS inoperative (which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation), all maintenance must be performed by an authorized NISSAN dealer.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system.
I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses (except “SEAT BELT-TENSIONER” connector) can be identified with yellow harness connector and with yellow harness protector or yellow insulation tape
before the harness connectors.
Precautions
I
I
I
YBR293
Use only “DOT 4” fluid from a sealed container.
Never reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately.
I To clean master cylinder parts, disc brake caliper parts or
wheel cylinder parts, use clean brake fluid.
I Never use mineral oils such as Petrol or kerosene. They
will ruin rubber parts of hydraulic system.
I Use flare nut wrench when removing and installing brake
tubes.
I Always torque brake lines when installing.
I Burnish the brake contact surfaces after refinishing or
replacing drums or rotors, after replacing pads or linings,
or if a soft pedal occurs at very low speed. Refer to “Brake
Burnishing Procedure”, “Check and Adjustment”, BR-5.
WARNING:
I Clean brakes with a vacuum dust collector to minimize risk
of health hazard from airborne materials.
I Avoid prolonged and repeated skin contact with brake
fluid.
I Wear protective clothing, including impervious gloves.
I Where there is a risk of eye contact, eye protection should
be worn — for example chemical goggles or face shield.
BR-3
PRECAUTIONS AND PREPARATION
Preparation
SPECIAL SERVICE TOOLS
Tool number
Tool name
Description
GG94310000
Flare nut torque wrench
Removing and installing each brake piping
KV991V0010
Brake fluid pressure
gauge
Measuring brake fluid pressure
HT72480000
Rear axle shaft bearing
puller
Removing rear wheel sensor rotor
BR-4
CHECK AND ADJUSTMENT
Checking Brake Fluid Level
I
I
I
Check fluid level in reservoir tank. It should be between Max.
and Min. lines on reservoir tank.
If fluid level is extremely low, check brake system for leaks.
When brake warning lamp comes on even when parking brake
lever is released, check brake system for leaks.
SBR849B
Checking Brake Line
CAUTION:
If leakage occurs around joints, retighten or, if necessary,
replace damaged parts.
1. Check brake lines (tubes and hoses) for cracks, deterioration
or other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.
SMA732A
Changing Brake Fluid
SBR992
CAUTION:
I Refill with new brake fluid “DOT 4”.
I Never reuse drained brake fluid.
I Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately. DO
NOT RUB IT OFF.
1. Connect a vinyl tube to each air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
3. Refill until new brake fluid comes out of each air bleeder valve.
Use same procedure as in bleeding hydraulic system to refill
brake fluid. Refer to “Bleeding Brake System”, “BRAKE
HYDRAULIC LINE”, BR-8.
Brake Burnishing Procedure
Burnish the brake contact surfaces according to the following procedure after refinishing or replacing rotors or drums, after replacing pads or linings, or if a soft pedal occurs at very low mileage.
CAUTION:
Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1. Drive the vehicle on a straight smooth road at 50 km/h (31
MPH).
2. Use medium brake pedal/foot to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot
pressure such that vehicle stopping time equals 3 to 5
seconds.
3. To cool the brake system, drive the vehicle at 50 km/h (31
MPH) for 1 minute without stopping.
4. Repeat steps 1 to 3 for 10 times or more to complete the
burnishing procedure.
BR-5
BRAKE HYDRAULIC LINE
W/O ABS
YBR256
BR-6
BRAKE HYDRAULIC LINE
WITH ABS
YBR257
BR-7
BRAKE HYDRAULIC LINE
Bleeding Brake System
SBR995
CAUTION:
I Carefully monitor brake fluid level at master cylinder during bleeding operation.
I If master cylinder is suspected to have air inside, bleed air
from master cylinder first. Refer to “Installation”, “MASTER CYLINDER”, BR-16.
I Fill reservoir with recommended brake fluid “DOT 4”. Make
sure it is full at all the times while bleeding air out of system.
I Place a container under master cylinder to avoid spillage
of brake fluid.
I For models with ABS, turn ignition switch to the OFF position and disconnect ABS fuse or battery cable.
I Bleed air in the following order:
Load Sensing Valve air bleeder (Models equipped with LSV)
"
Left rear brake
"
Right rear brake
"
Left front brake
"
Right front brake
1. Connect a transparent vinyl tube to air bleeder valve.
2. Fully depress brake pedal several times.
3. With brake pedal depressed, open air bleeder valve to release
air.
4. Close air bleeder valve.
5. Release brake pedal slowly.
6. Repeat steps 2 through 5 until clear brake fluid comes out of
air bleeder valve.
7. Tighten air bleeder valve
: 7 - 9 N⋅m (0.7 - 0.9 kg-m, 61 - 78 in-lb)
SBR419C
BR-8
BRAKE HYDRAULIC LINE
Removal
YBR293
CAUTION:
I Use suitable tool for assembly and disassembly of brake
lines and hoses.
I Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately. DO
NOT RUB IT OFF.
I All hoses must be free from excessive bending, twisting
and pulling.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depressing
brake pedal.
3. Remove flare nut securing brake tube to hose, then withdraw
lock spring.
4. Cover openings to prevent entrance of dirt whenever disconnecting hydraulic line.
Inspection
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
Installation
YBR293
CAUTION:
I Refill with new brake fluid “DOT 4”.
I Never reuse drained brake fluid.
1. Tighten all flare nuts and connecting bolts.
Flare nut:
: 9 - 11 N⋅m (0.9 - 1.1 kg-m, 78 - 95 in-lb)
Connecting bolt:
: 17 - 20 N⋅m (1.7 - 2.0 kg-m, 12 - 14 ft-lb)
2. Refill until new brake fluid comes out of each air bleeder valve.
3. Bleed air. Refer to “Bleeding Brake System”, BR-8.
BR-9
LOAD SENSING VALVE
Removal and Installation
NBR312
BR-10
LOAD SENSING VALVE
Removal
CAUTION:
I Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas, wash it away with water immediately. DO
NOT RUB IT OFF.
I Remove flare nuts and LSV bolts.
Installation
YBR293
CAUTION:
I Refill with new brake fluid “DOT 4”.
I Never reuse drained brake fluid.
I Check level in brake fluid reservoir.
1. Tighten provisionally flare nuts.
2. Tighten LSV bolts.
: 20 - 24 N⋅m (2.0 - 2.4 kg-m, 14 - 17 ft-lb)
3. Tighten flare nuts.
: 15 - 18 N⋅m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
4. Bleed air. Refer to “Bleeding Brake System”, “BRAKE
HYDRAULIC LINE”, BR-8.
5. Adjust load sensing valve (LSV). Refer to “Inspection and
Adjustment”, “LOAD SENSING VALVE”, BR-12.
BR-11
LOAD SENSING VALVE
Inspection and Adjustment
CAUTION:
I Check level in brake fluid reservoir.
I Refill with recommended brake fluid “DOT 4”.
I Never reuse drained brake fluid.
I Be careful not to splash brake fluid on painted areas; it
may cause paint damage. If brake fluid is splashed on
painted areas wash it away with water immediately. DO
NOT RUB IT OFF.
1. Before adjusting load sensing valve spring length, check for
proper installation and abnormal wear of brake pads and
shoes.
2. Remove the air bleeder from the wheel caliper, and install a
pressure gauge (A) to the bleed valve hole.
EBR019
3. Bleed the air from the front brake piping.
EBR020
4. Remove the air bleed valve from the rear wheel cylinder, and
install a pressure gauge (B) to the bleed valve hole.
EBR021
BR-12
LOAD SENSING VALVE
Inspection and Adjustment (Cont’d)
5. Bleed the air from the rear brake piping.
EBR022
NBR313
6. To adjust the LSV correctly, proceed as follows:
a. With unladen vehicle (12 liters of fuel, radiator coolant and
engine oil are full). Spare tire, hand tools and mats in designated positions. Check the length of LSV spring “L”.
b. If the spring length is different from that specified, move the
regulation lever (2) until the specified value is obtained. Move
the LSV lever (1) until it contacts the stopper bolt and recheck
the spring length.
Sensor spring length “L”
Hardtop: 201 mm (7.913 in)
Wagon: 197.5 mm (7.776 in)
NOTE: Do not disturb stopper bolt.
c. Start the engine and run it at idling speed.
d. Slowly depress the brake pedal until an input pressure of 4,805
kPa (48.1 bar, 49 kg/cm2, 697 psi) is obtained (at the front axle
pressure gauge) and an output pressure of 1,736 - 2,501 kPa
(18 - 26 bar, 17.7 - 25.5 kg/cm2, 252 - 363 psi) is obtained (at
the rear axle pressure gauge).
If the output pressure at the rear axle pressure gauge is not within
the specified values, adjust LSV spring length as described under
b) until the output pressure measured is within the specified range.
Unit: kPa (bar, kg/cm2, psi)
EBR026
Front axle*
4,805 (48.1, 49.0, 697)
Rear axle*
1,736 - 2,501 (18 - 26, 17.7 - 25.5, 252 - 363)
* Load conditions as indicated under 6.a, driver seat occupied.
BR-13
BRAKE PEDAL AND BRACKET
Removal and Installation
NBR269
BR-14
BRAKE PEDAL AND BRACKET
Inspection
Check brake pedal for following items:
I Brake pedal bend
I Clevis pin deformation
I Crack of any welded portion
I Crack or deformation of clevis pin stopper
SBR997
Adjustment
Check brake pedal free height from dash reinforcement panel.
H: Free height
Refer to SDS, BR-85.
D: Full stroke
Refer to SDS, BR-85.
C: Clearance between pedal stopper and threaded end
of stop lamp switch
0.3 - 1.0 mm (0.012 - 0.039 in)
A: Pedal free play
1.0 - 3.0 mm (0.039 - 0.118 in)
EBR200
If necessary, adjust brake pedal free height.
1. Loosen lock nut and adjust pedal free height by turning brake
booster input rod. Then tighten lock nut.
Make sure that tip of input rod stays inside of clevis as shown.
2. Loosen lock nut and adjust clearance “C” with stop lamp switch.
Then tighten lock nuts.
3. Check pedal free play.
Make sure that stop lamps go off when pedal is released.
4. Check brake system for leaks, accumulation of air or any damage to components (master cylinder, etc.); then make necessary repairs.
YBR300
BR-15
MASTER CYLINDER
YBR258
Removal
EBR080
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately. DO NOT RUB.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve, depressing brake
pedal to empty fluid from master cylinder.
3. Remove brake pipe flare nuts.
4. Remove master cylinder mounting nuts.
5. Remove protector of master cylinder, and avoid scratching the
surface of master cylinder during removal.
CAUTION:
Do not disassemble master cylinder.
NOTE:
If it is necessary to change the brake fluid reservoir, remove it
as shown in the illustration on the left, while holding the seals
with one hand.
It is not necessary to replace the seals if they are in a good
condition.
Installation
CAUTION:
I Refill with new brake fluid “DOT 4”.
I Never reuse drained brake fluid.
1. Place master cylinder onto brake booster and secure mounting
nuts lightly.
2. Fit flare nuts to master cylinder.
3. Tighten mounting nuts.
: 21 - 29 N⋅m (2.1 - 3.0 kg-m, 15 - 22 ft-lb)
4. Tighten flare nuts.
: 15 - 18 N⋅m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
5. Bleed air. Refer to “Bleeding Brake System”, “BRAKE
HYDRAULIC LINE”, BR-8.
BR-16
BRAKE BOOSTER
Removal and Installation
YBR259
Inspection
OPERATING CHECK
I
I
Depress brake pedal several times with engine off, and check
that there is no change in pedal stroke.
Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
SBR002A
AIRTIGHT CHECK
I
I
Start engine, and stop it after one or two minutes. Depress
brake pedal several times slowly. If pedal goes further down the
first time and gradually rises after second or third time, booster
is airtight.
Depress brake pedal while engine is running, and stop engine
with pedal depressed. If there is no change in pedal stroke after
holding pedal down 30 seconds, brake booster is airtight.
SBR365A
OUTPUT ROD LENGTH CHECK
1. Apply vacuum of −66.7 kPa (−667 mbar, −500 mmHg, −19.69
inHg) to brake booster with a manual vacuum pump and check
output rod length “A”.
Specified length “A”:
22.15 - 22.45 mm (0.872 - 0.884 in)
(The length “A” in this case is the distance from end of output
rod to outside of brake booster, when the specified vacuum is
applied.)
EBR090
BR-17
BRAKE BOOSTER
Inspection (Cont’d)
2. Check output rod length “L” when brake booster doesn’t work.
Specified length “L”:
129.2 - 130.2 mm (5.09 - 5.13 in)
YBR294
Installation
CAUTION:
I Be careful not to deform or bend brake pipes, during installation of booster.
I Replace clevis pin if damaged.
I Refill with new brake fluid “DOT 4”.
I Never reuse drained brake fluid.
I Take care not to damage brake booster mounting bolt
thread when installing. Due to the acute angle of
installation, the threads can be damaged on the metal surrounding the dash panel holes.
1. Before fitting booster, temporarily adjust clevis to dimension
shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket to
brake booster) lightly. (Join brake booster and brake pedal
bracket to the front end of the vehicle interior).
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
: 20 - 25 N⋅m (1.3 - 1.6 kg-m, 10 - 12 ft-lb)
5. Install master cylinder. Refer to “Installation”, “MASTER
CYLINDER”, BR-16.
6. Bleed air. Refer to “Bleeding Brake System”, “BRAKE
HYDRAULIC LINE”, BR-8.
BR-18
VACUUM HOSE
Removal and Installation
YBR260
BR-19
VACUUM HOSE
Removal and Installation (Cont’d)
YBR292
CAUTION:
When installing vacuum hoses, pay attention to the following
points.
I Do not apply any oil or lubricants to vacuum hose and
check valve.
I Insert vacuum tube into vacuum hose over a length of min.
24 mm (0.94 in) as shown.
Take care to main vacuum hoses in their original direction and
position.
SBR225B
BR-20
VACUUM HOSE
EBR008
Inspection
HOSES AND CONNECTORS
I
I
Check condition of vacuum hoses and connectors.
Check vacuum hoses and check valve for air tightness.
CHECK VALVE
I
Check vacuum with a manual vacuum pump.
Connect to booster
side
Vacuum should exist.
Connect to engine
side
Vacuum should not exist.
EBR009
VACUUM WARNING SWITCH
Test continuity though vacuum warning switch with an ohmmeter
and vacuum pump.
Less than 26.7 kPa
(267 mbar, 200 mmHg,
7.87 inHg)
0Ω
Vacuum
33.3 kPa
(333 mbar, 250 mmHg,
9.84 inHg) or more
SBR007A
BR-21
Ω
VACUUM HOSE
Inspection (Cont’d)
VACUUM PUMP (TD27Ti ENGINE)
1. Install vacuum gauge.
2. Run engine at 1,000 rpm or more.
3. Check vacuum.
Specified vacuum:
93.3 kPa
(933 mbar, 700 mmHg, 27.56 inHg) or more
NBR004
VACUUM PUMP (ZD30DDTi ENGINE)
Refer to EM section, “INSPECTION” in “VACUUM PUMP —
Removal and Installation”.
BR-22
VACUUM PUMP (TD27Ti engine model)
Removal and Installation
NBR131
I Drain oil from vacuum pump before removal.
Manually rotate fan belt clockwise to discharge any oil which
may have accumulated in vacuum pump.
I
I
Install vane so that its round surface faces pump housing.
After installing vacuum pump assembly, apply 5 m (0.2 Imp fl
oz) of engine oil into vacuum pump assembly. Then, make sure
that pulley can be smoothly rotated by hand.
NBR132
Inspection
Clean all parts and check them as follows:
I Check for wear or scratches on mating surfaces of rotor and
vacuum pump housing and on rotor and center plate. If wear
or scratches are noted, replace those parts.
I Check for wear or scratches on vanes. If necessary, replace.
NBR133
BR-23
VACUUM PUMP (TD27Ti engine model)
Inspection (Cont’d)
I
I
I
Check inner wall of vacuum pump housing for wear. If
necessary, replace.
Check rotor shaft for wear. If necessary, replace.
Check valve locations and copper washers for bends or deformation. If necessary, replace.
NBR134
I
Check that valve operates smoothly when slightly pushed.
Replace if necessary.
I
Check for air leakage with 98 to 490 kPa (1.0 to 4.9 bar, 1 to
5 kg/cm2, 14 to 71 psi) of air pressure.
Replace if necessary.
SBR194
SBR195
BR-24
VACUUM PUMP (ZD30DDTi engine model)
Removal and Installation
Refer to EM section, “VACUUM PUMP — Removal and Installation”.
BR-25
FRONT DISC BRAKE
YBR297
PRECAUTION:
Clean all brake assembly parts with a vacuum dust collector
to prevent particles from spreading through work area.
Pad Replacement
1. Loosen brake fluid reservoir cap.
2. Remove lower pin bolt.
SBR081A
BR-26
FRONT DISC BRAKE
Pad Replacement (Cont’d)
3. Swing cylinder body upward. Then remove pad and anti-noise
shims.
CAUTION:
I When cylinder body is swung up, do not depress brake
pedal because piston will pop out.
I Ensure that brake fluid does not come into contact with
dustcover and rotor.
I Be careful not to twist brake hoses.
Brake pad thickness (new):
10 mm (0.39 in)
Wear limit (min. thickness):
2 mm (0.08 in)
I After installing new brake pads, check brake fluid level at
brake fluid reservoir.
NBR207
Removal
I
Remove torque member fixing bolts and union bolt.
SBR012C
Disassembly
Push out piston with dust cover with compressed air.
Use a wooden block so that the 2 pistons come out evenly.
CAUTION:
I Wear protecting clothes and safety goggles.
I Do not hold your fingers in front of the pistons.
I Be careful not to scratch piston and/or cylinder faces.
SBR085A
Inspection
INSPECTION OF BRAKE DRAG FORCE
“Residual pair” describes the friction pressure of the disc brake
shoes against the disc when the brake pedal is not applied.
1. Swing cylinder body upward.
2. Make sure that wheel bearing is adjusted properly. Refer to
section FA.
3. Measure rotating force (F1).
SBR168A
BR-27
FRONT DISC BRAKE
Inspection (Cont’d)
4.
5.
6.
7.
8.
Install caliper with pads to the original position.
Depress brake pedal for 5 seconds.
Release brake pedal, rotate disc rotor 10 revolutions.
Measure rotating force (F2).
Calculate brake drag force by subtracting F1 from F2.
Maximum brake drag force (F2 — F1):
103.0 N (10.5 kg, 23.2 lb)
SBR130A
If it is not within specification, check pins and pin boots in
caliper.
I Make sure that wheel bearing is adjusted properly.
I Disc pads and disc rotor must be dry.
SBR041A
DISC PAD
Check disc pad for wear or damage.
Pad wear limit (A):
2.0 mm (0.079 in)
SMA364A
Assembly
Fit new piston seals.
Lightly apply clean brake fluid “DOT 4” to piston outer face.
1. Insert piston seal into groove on cylinder body.
2. Install piston into cylinder body.
3. Install piston boot and secure properly.
NBR007
Inspection
CYLINDER BODY
I
SBR574
Check inside surface of cylinder for score, rust, wear, damage
or presence of foreign materials. If any of the above conditions
are observed, replace cylinder body.
I Minor damage from rust or foreign materials may be eliminated
by polishing the surface with a fine emery paper. Replace cylinder body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
BR-28
FRONT DISC BRAKE
Inspection (Cont’d)
PISTON
Check outside surface of piston for score, rust, wear, damage or
presence of foreign materials. Replace if any of the above conditions are observed.
CAUTION:
Piston sliding surface is plated. Do not polish with emery
paper even if rust or foreign materials are stuck to sliding
surface.
PIN, PIN BOLT AND PIN BOLT
Check for wear, cracks or other damage. Replace if any of the
above conditions are observed.
ROTOR
Rubbing surface
Check rotor for roughness, cracks or chips.
Runout
SBR089A
1. Secure rotor to wheel hub with at least two nuts.
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the
specifications before measuring. Refer to section FA.
Maximum runout:
0.07 mm (0.0028 in)
3. If the runout is out of specification, find minimum runout position as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor to wheel hub with
nuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position can
be found.
4. If the runout is still out of specification, turn rotor with on-car
brake lathe.
Thickness
Standard thickness:
26.0 mm (1.02 in)
Minimum thickness:
24.0 mm (0.94 in)
SBR090A
BR-29
FRONT DISC BRAKE
Installation
CAUTION:
I Refill with new brake fluid “DOT 4”.
I Never reuse drained brake fluid.
1. Install caliper assembly.
2. Install brake hose to caliper securely taking care that brake
hose is not trapped between any suspension part and that
hoses are not twisted.
3. Bleed air. Refer to “Bleeding Brake System”, “BRAKE
HYDRAULIC LINE”, BR-8.
SBR014C
BR-30
REAR DRUM BRAKE
YBR298
q
1
q
2
q
3
q
4
q
5
q
6
q
7
Wheel cylinder assembly
Boot
Piston
Piston cup
Cylinder body
Spring
Retaining shoe spring
q
8
q
9
q
10
q
11
q
12
q
13
q
14
Hold down retainer
Shoe hold-down spring
Shoe hold-down pin
Pawl
Adjuster assembly
Trailing shoe
Leading shoe
BR-31
q
15
q
16
q
17
q
18
q
19
q
20
Back plate
Plug
Shoe return spring
Toggle lever
Pin
Dust cap
REAR DRUM BRAKE
Removal
WARNING:
Clean brake lining with a vacuum dust collector.
CAUTION:
Make sure parking brake lever is released completely.
1. Release parking brake lever fully, then remove drum.
If drum is hard to remove, screw two bolts in the provided
holes of the drum and tighten them gradually.
If the drum cannot be removed after carrying out this
operation, refer to “Inspection”, “PARKING BRAKE
CONTROL”, BR-35.
SBR093A
BR-32
REAR DRUM BRAKE
Shoe Replacement
When installing new shoes, springs should be changed as well.
Check lining thickness.
Standard lining thickness:
Trailing: 3.95 mm (0.156 in)
Leading: 8.95 mm (0.352 in)
Lining wear limit (A):
1.52 mm (0.0598 in)
SBR021A
Inspection
WHEEL CYLINDER
I
I
Check wheel cylinder for leakage.
Check for wear, damage and loose conditions.
Replace if any such condition exists.
SBR018C
DRUM
Maximum inner diameter:
282 mm (11.10 in)
Out of roundness:
0.05 mm (0.019 in) or less
SBR019C
I
I
I
Contact surface should be fine finished with No. 120 to 150
emery paper.
If any scratches or wear are detected, adjust the alignment of
the drum.
After brake drum has been completely reconditioned or
replaced, check drum and shoes for proper contact pattern.
Installation
Always perform shoe clearance adjustment. Refer
“Adjustment”, “PARKING BRAKE CONTROL”, BR-35.
1. Fit adjuster assembly.
EBR089
BR-33
to
REAR DRUM BRAKE
Installation (Cont’d)
2. Apply brake grease to the contact areas shown at left.
SBR020C
3. Shorten adjuster by rotating it, so that shoe outer diameter is
279 - 279.5 mm (10.98 - 11 in).
I Pay attention to direction of adjuster assembly.
EBR016
4. Connect parking brake cable to toggle lever.
5. Install all parts.
6. Check all parts are installed properly.
Pay attention to direction of adjuster assembly.
7. Install brake drum.
8. When installing new wheel cylinder or overhauling wheel
cylinder, bleed air. Refer to “Bleeding Brake System”, “BRAKE
HYDRAULIC LINE”, BR-8.
9. At completion, apply brake pressure by pressing the brake
pedal approximately 20 times at half stroke.
NBR344
BR-34
PARKING BRAKE CONTROL
NBR124
Removal and Installation
1. To remove parking brake cable, first remove center console.
2. Disconnect warning lamp connector.
3. Remove bolts, slacken off and remove adjusting nut.
SBR101B
Inspection
1. Check control lever for wear or other damage. Replace if necessary.
2. Check wires for discontinuity or deterioration. Replace if necessary.
3. Check warning lamp and switch. Replace if necessary.
4. Check parts at each connecting portion and, if deformed or
damaged, replace.
Adjustment
1.
a.
b.
2.
SBR353B
Adjust clearance between shoe and drum as follows:
Release parking brake lever and loosen adjusting nut.
Depress brake pedal fully at least 10 times with engine running.
Apply the handbrake, allowing the handbrake grip to move 6
notches. You can adjust the handbrake travel by using the
adjusting nut. To complete this adjustment, you will need a
dynamo meter to check the amount of load required to move
from 9 to 10 notches. If the load exceeds 20 kg, the cable will
have to be loosened with the help of the adjusting nut.
Number of notches:
9 - 10
If the load is less than 20 kg, the cable should be tightened.
BR-35
PARKING BRAKE CONTROL
Adjustment (Cont’d)
3. Apply the handbrake, using the specified pressure. Check the
travel to see that the handbrake is working smoothly.
SBR033A
4. Bend parking brake warning lamp switch plate so that brake
warning lamp comes on when parking brake lever is pulled “A”
notches.
Number of “A” notches: 1 or less
BR-36
ANTI-LOCK BRAKE SYSTEM
Purpose
The Anti-lock Brake System (ABS) with an integrated Electronic Brake force Distribution (EBD) system consists of electronic and hydraulic components. It allows you to control the braking force so that wheel lock can
be avoided during braking.
The advantages of ABS with EBD
1) Better tracking performance through improved steering wheel control.
2) Improved maneuverability and safer vehicle control.
3) Improved vehicle stability by preventing flat spins.
4) Shorter stopping distance and optimal utilisation of the rear brakes under many different circumstances.
Operation
I
I
I
I
ABS with EBD has self-test capabilities. The ABS warning lamp is illuminated for 1 second each time the
ignition switch is turned “ON”. After the engine is started, the ABS warning lamp turns off. An ABS self-test
is performed the first time the vehicle reaches 6 km/h (4 MPH) to ensure the system is operational. A
mechanical noise may be heard as the ABS performs this self-test and is a normal part of the self-test
feature. If a malfunction is detected during this check, the ABS warning lamp will stay on.
During the self-test, it also performs a EBD check when it detects a failure the ABS warning light will go
on simultaneously with the brake warning light and an audible sound will sound constantly.
EBD system will only operate when the ABS is not in active status and it uses the inlet valves of ABS control unit to limit the pressure to the rear wheels when they tend to go into slip.
When the vehicle speed is less than 10 km/h (6 MPH) the ABS system does not operate.
While driving, a mechanical noise may be heard during ABS operation, this is a normal system condition.
ABS Hydraulic Circuit
NBR346
q
1
q
2
q
3
Inlet solenoid valve
Outlet solenoid valve
Reservoir
q
4
q
5
q
6
q
7
Pump
Motor
BR-37
By pass check valve
Damper
ANTI-LOCK BRAKE SYSTEM
YBR262
System Description
Sensor
The sensor unit consists of a gear-shaped sensor rotor and a sensor element. The element contains a bar magnet around which a
coil is wound. The sensor is installed on the back of the brake rotor
and the rear brake drum.
As the wheel rotates, the sensor generates a sine-wave pattern.
The frequency and voltage increase(s) as the rotating speed
increases.
SBR124B
Control unit
The control unit computes the wheel rotating speed by the signal
current sent from the sensor. Then it supplies a DC current to the
actuator solenoid valve. It also controls ON-OFF operation of the
valve relay and rotor relay. If any electrical malfunction should be
detected in the ABS or EBD system, the control unit causes the
warning lamp(s) to light up, combined with an audible sound.
In this condition, the ABS or EBD will be deactivated by the control
unit, and the vehicle’s brake system reverts to normal operation.
(Fail-safe mode)
YBR263
BR-38
ANTI-LOCK BRAKE SYSTEM
System Description (Cont’d)
G SENSOR
The G sensor analyses deceleration during braking to determine whether the vehicle is being driven on a road
with low surface resistance (µ) (snow-covered road, etc.). The ABS control unit uses the signal from the
deceleration sensor to compensate for road surface conditions when controlling the braking operation.
NBR136
BR-39
ANTI-LOCK BRAKE SYSTEM
System Description (Cont’d)
ACTUATOR AND ELECTRIC UNIT
YBR299
The actuator and electric unit contains:
I An electric motor and pump
I Two relays
I Six solenoid valves, each inlet and outlet for
— LH front
— RH front
— Rear
I ABS control unit
These components control the hydraulic circuit. The ABS control
unit directs the actuator to increase, hold or decrease hydraulic
pressure to all or individual wheels. The ABS actuator and electric
unit cannot be disassembled and has to be serviced as an assembly.
BR-40
ANTI-LOCK BRAKE SYSTEM
System Description (Cont’d)
ABS actuator operation
Inlet solenoid
valve
Outlet solenoid
valve
OFF (Open)
OFF (Closed)
Master cylinder brake fluid pressure is directly transmitted to caliper via the inlet solenoid valve.
Pressure hold
ON (Closed)
OFF (Closed)
Hydraulic circuit is shut off to hold the caliper brake
fluid pressure.
Pressure
decrease
ON (Closed)
ON (Open)
Caliper brake fluid is sent to reservoir via the outlet
solenoid valve. Then it is pushed up to the master
cylinder by pump.
Pressure
increase
OFF (Open)
OFF (Closed)
Master cylinder brake fluid pressure is transmitted to
caliper.
Normal brake operation
ABS operation
BR-41
ANTI-LOCK BRAKE SYSTEM
Removal and Installation
CAUTION:
Be careful not to damage sensor edge and sensor rotor teeth.
When removing the front or rear wheel hub assembly, disconnect the ABS wheel sensor from the assembly and move it
away.
FRONT WHEEL SENSOR
NBR122
REAR WHEEL SENSOR
SBR399D
BR-42
ANTI-LOCK BRAKE SYSTEM
Removal and Installation (Cont’d)
FRONT SENSOR ROTOR
Removal
1. Remove the drive shaft and rear wheel hub. Refer to “Front axle
— drive shaft” in FA section and “Rear axle” in RA section.
2. Remove the sensor rotor using suitable puller, drift and bearing replacer.
YBR295
Installation
Install the sensor rotor. For front sensor rotor, use hammer and
wooden block. For rear sensor rotor, use suitable drift and press.
I Always replace sensor rotor with new one.
YBR296
BR-43
ANTI-LOCK BRAKE SYSTEM
Removal and Installation (Cont’d)
REAR SENSOR ROTOR
Removal
I
Remove the sensor rotor using Tool.
SBR401D
Installation
Install the sensor rotor using suitable drift and press.
I Always replace sensor rotor with new one.
I Pay attention to the direction of front sensor rotor as shown in
figure.
SBR402D
CONTROL UNIT
Location: Built-in ABS actuator.
When disconnecting the harness connector, pull the lever as
shown in figure.
NBR212
G SENSOR
Always replace G sensor if bumped or dropped. Otherwise,
performance characteristics of G sensor will be changed,
which in turn alters ABS control performance characteristics.
NBR127
BR-44
ANTI-LOCK BRAKE SYSTEM
Removal and Installation (Cont’d)
ACTUATOR
YBR299
Removal
1. Disconnect battery cable.
2. Drain brake fluid. Refer to BR-5.
3. Unlock the slider then disconnect the electrical harness connectors from ABS control unit.
4. Identify each brake pipe with corresponding actuator port hole
and mark them accordingly.
5. Disconnect brake pipes and move them away from actuator. Do
not force brake pipes so as to kink them or bend them excessively.
Ensure that brake fluid does not come into contact with
any parts.
BR-45
ANTI-LOCK BRAKE SYSTEM
Removal and Installation (Cont’d)
6. Loosen/remove mounting nuts between actuator and bracket.
Installation
CAUTION:
After installation, pay attention to the following points:
I Refill brake fluid and bleed air. Refer to “CHECK AND
ADJUSTMENT”, BR-5 and “Bleeding Brake System”,
“BRAKE HYDRAULIC LINE”, BR-8, respectively.
1. Install actuator on bracket without tightening fixings.
2. Assemble brake tubes to actuator without tightening tube nuts.
Ensure that correct tubes are connected to each port.
3. Fully tighten actuator and bracket fixings to specified torque.
4. Fully tighten flare nuts to specified torque, BR-9.
5. Secure ABS control unit harness connector and battery cable.
BR-46
TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick
and Accurate Repair
INTRODUCTION
SEF233G
SEF234G
The ABS system has an electronic control unit to control major
functions. The control unit accepts input signals from sensors and
uses this data to compute control characteristics to instantly drive
the actuators. It is essential that both kinds of signal are accurate
and stable. It is also important to check for conventional brake
system problems: such as air leaks in booster lines, lack of brake
fluid, or other problems with the brake system.
It is much more difficult to diagnose a problem that occurs intermittently rather than catastrophically. Most intermittent problems are
caused by poor electric connections or faulty wiring. In this case,
careful checking of suspicious circuits may help prevent the
replacement of good parts.
A visual check may not be sufficient to determine the cause of the
problems, so a road test should also be conducted.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with an ABS complaint. The customer
is a very good source of information on such problems; especially
intermittent ones. Through the talks with the customer, find out what
symptoms are present and under what conditions they occur.
Start your diagnosis by looking for “conventional” problems first.
This is one of the best ways to troubleshoot brake problems on an
ABS controlled vehicle.
BR-47
TROUBLE DIAGNOSES
Component Parts and Harness Connector
Location
YBR264
BR-48
TROUBLE DIAGNOSES
Circuit Diagram for Quick Pinpoint Check
YBR244
BR-49
TROUBLE DIAGNOSES
Wiring Diagram — ABS —
LHD MODELS
YBR245
BR-50
TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)
YBR246
BR-51
TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)
YBR247
BR-52
TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)
YBR248
BR-53
TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)
RHD MODELS
YBR249
BR-54
TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)
YBR250
BR-55
TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)
YBR251
BR-56
TROUBLE DIAGNOSES
Wiring Diagram — ABS — (Cont’d)
YBR252
BR-57
TROUBLE DIAGNOSES
CONSULT-II
CONSULT-II APPLICATION TO ABS
SELF-DIAGNOSTIC
RESULTS
DATA MONITOR
ACTIVE TEST
Front right wheel sensor
X
X
—
Front left wheel sensor
X
X
—
Rear right wheel sensor
X
X
—
Rear left wheel sensor
X
X
—
G switch (G sensor)
X
X
X
Stop lamp switch
—
X
—
Front right inlet solenoid valve
X
X
X
Front right outlet solenoid valve
X
X
X
Front left inlet solenoid valve
X
X
X
Front left outlet solenoid valve
X
X
X
Rear inlet solenoid valve
X
X
X
Rear outlet solenoid valve
X
X
X
Actuator solenoid valve relay
X
X
—
Actuator motor relay
(ABS MOTOR is shown on the Data Monitor
screen.)
X
X
X
ABS warning lamp
—
X
—
Brake warning lamp
—
X
—
Battery voltage
X
X
—
ABS Operating Signal
—
—
—
ITEM
X: Applicable
—: Not applicable
ECU (ABS control unit) part number mode
Ignore the ECU part number displayed in the ECU PART NUMBER MODE. Refer to parts catalog to order
the ECU.
BR-58
TROUBLE DIAGNOSES
CONSULT-II Inspection Procedure
SELF-DIAGNOSIS PROCEDURE
1) Turn ignition switch to OFF position.
2) Connect CONSULT-II to Data Link Connector.
H
YBR265
1) Start engine.
2) Drive vehicle over 30 km/h (19 MPH)
for at least one minute.
H
1) Stop vehicle with engine running
and touch “START” on CONSULT-II screen.
2) Touch “ABS”.
C2NCS01
3) Touch “SELF-DIAG RESULTS”.
I The screen shows the detected malfunction and how many times the ignition
switch has been turned since the malfunction.
H
Make the necessary repairs following the
diagnostic procedures.
H
C2SSE01
After the malfunctions are repaired, erase
the self-diagnostic results stored in the
control unit by touching “ERASE”.
H
Check warning lamp(s) for deactivation
after driving vehicle over 30 km/h (19
MPH) for at least one minute.
H
Test the ABS system in a safe area to
verify that it functions properly.
C2SDM01
H
END
Note: “SELF-DIAG RESULTS” screen shows the detected malfunction and
how many times the ignition switch has been turned since the malfunction.
C2SDR01
BR-59
TROUBLE DIAGNOSES
CONSULT-II Inspection Procedure (Cont’d)
SELF-DIAGNOSTIC RESULTS MODE
Diagnostic item
FR RH SENSOR★
[OPEN]
FR LH SENSOR★
[OPEN]
RR RH SENSOR★
[OPEN]
RR LH SENSOR★
[OPEN]
FR RH SENSOR★
[SHORT]
FR LH SENSOR★
[SHORT]
RR RH SENSOR★
[SHORT]
RR LH SENSOR★
[SHORT]
ABS SENSOR★
[ABNORMAL SIGNAL]
FR RH IN ABS SOL
[OPEN, SHORT]
FR LH IN ABS SOL
[OPEN, SHORT]
FR RH OUT ABS SOL
[OPEN, SHORT]
FR LH OUT ABS SOL
[OPEN, SHORT]
RR IN ABS SOL
[OPEN, SHORT]
RR OUT ABS SOL
[OPEN, SHORT]
ABS ACTUATOR RELAY
[ABNORMAL]
ABS MOTOR RELAY
[ABNORMAL]
BATTERY VOLT
[VB-LOW]
CONTROL UNIT
G-SENSOR
[ABNORMAL]
Diagnostic item is detected when . . .
I Circuit for front right wheel sensor is open.
(An abnormally high input voltage is entered.)
I Circuit for front left wheel sensor is open.
(An abnormally high input voltage is entered.)
I Circuit for rear right sensor is open.
(An abnormally high input voltage is entered.)
I Circuit for rear left sensor is open.
(An abnormally high input voltage is entered.)
I Circuit for front right wheel sensor is shorted.
(An abnormally low input voltage is entered.)
I Circuit for front left wheel sensor is shorted.
(An abnormally low input voltage is entered.)
I Circuit for rear right sensor is shorted.
(An abnormally low input voltage is entered.)
I Circuit for rear left sensor is shorted.
(An abnormally low input voltage is entered.)
I Teeth damage on sensor rotor or misalignment of wheel sensor.
(Abnormal wheel sensor signal is entered.)
I Circuit for front right inlet solenoid valve is open or shorted.
(An abnormally low output voltage is entered.)
I Circuit for front left inlet solenoid valve is open or shorted.
(An abnormally low output voltage is entered.)
I Circuit for front right outlet solenoid valve is open or shorted.
(An abnormally low output voltage is entered.)
I Circuit for front left outlet solenoid valve is open or shorted.
(An abnormally low output voltage is entered.)
I Circuit for rear right outlet solenoid valve is open or shorted.
(An abnormally high output voltage is entered.)
I Circuit for rear left outlet solenoid valve is open or shorted.
(An abnormally high output voltage is entered.)
I Actuator solenoid valve relay is ON, even if control unit sends OFF signal.
I Actuator solenoid valve relay is OFF, even if control unit sends ON signal.
I Circuit for ABS motor relay is open or shorted.
I Circuit for actuator motor is open or shorted.
I Actuator motor relay is stuck.
Diagnostic
procedure
4
4
4
4
4
4
4
4
4
3
3
3
3
3
3
6
5
I Power source voltage supplied to ABS control unit is abnormally low.
7
I Function of calculation in ABS control unit has failed.
9
I G sensor is open.
8
★ If a tire slips on rough roads for more than 10 seconds, the ABS warning lamp may come on. In this case, the malfunctioning code
regarding the wheel sensors may be memorized. Turn off the ignition switch, restart the engine and drive the vehicle at speeds
above 30 km/h (19 MPH).
BR-60
TROUBLE DIAGNOSES
CONSULT-II Inspection Procedure (Cont’d)
DATA MONITOR PROCEDURE
1) Turn ignition switch to the OFF position.
2) Connect CONSULT-II to Data Link Connector.
3) Turn ignition switch to the ON position.
H
1) Touch “START” on CONSULT-II screen.
2) Touch “ABS”.
3) Touch “DATA MONITOR”.
C2NCS01
H
1) Select “SELECT MONITOR ITEM”.
H
Carry out the monitor test under the condition as described in page BR-62.
C2SSE01
C2SDM01
C2SMI01
BR-61
TROUBLE DIAGNOSES
CONSULT-II Inspection Procedure (Cont’d)
DATA MONITOR MODE
MONITOR ITEM
CONDITION
SPECIFICATION
FR RH SENSOR
FR LH SENSOR
REAR RH SENSOR
REAR LH SENSOR
Drive vehicle.
(Each wheel is rotating.)
Wheel speed signal
Almost the same speed as speedometer.
STOP LAMP SW
Brake is depressed.
Depress the pedal: ON
Release the pedal: OFF
G-SWITCH
Vehicle is driven.
Vehicle is stopped.
Brake is applied.
When driving or stopping vehicle with a force of less than 0.3G:
ON
When driving or stopping vehicle with a force of 0.3G or more:
OFF
FR RH IN SOL
FR RH OUT SOL
FR LH IN SOL
FR LH OUT SOL
RR IN SOL
RR OUT SOL
1. Drive vehicle at speeds over
30 km/h (19 MPH) for at
least one minute.
2. Engine is running.
Operating conditions for each solenoid valve are indicated.
ABS is not operating: OFF
MOTOR RELAY
ABS is not operating: OFF
ABS is operating: ON
ACTUATOR RELAY
Ignition switch in the “ON” position (Engine stops): OFF
Engine running: ON
WARNING LAMP
BATTERY VOLT
Ignition switch is set to the
“ON” position or engine is running.
Warning lamp is turned on: ON
Warning lamp is turned off: OFF
Power supply voltage for control unit
BR-62
TROUBLE DIAGNOSES
CONSULT-II Inspection Procedure (Cont’d)
ACTIVE TEST PROCEDURE
I
I
When conducting Active test, vehicle must be stationary.
When ABS warning lamp stays on, never conduct Active test.
1) Turn ignition switch to the “LOCK” position.
2) Connect CONSULT-II to Data Link Connector.
3) Start engine.
H
C2NCS01
1) Touch “START” on CONSULT-II screen.
2) Touch “ABS”.
3) Touch “ACTIVE TEST”.
H
1) Select active test item by touching screen.
2) Touch “START”.
H
Carry out the active test by touching screen key.
C2SSE01
C2SDM01
C2STI01
C2FRS01
BR-63
TROUBLE DIAGNOSES
CONSULT-II Inspection Procedure (Cont’d)
ACTIVE TEST MODE
TEST ITEM
CONDITION
JUDGEMENT
Brake fluid pressure control operation
FR RH SOLENOID
FR LH SOLENOID
RR SOLENOID
Engine is running.
OUT SOL
OFF
ON
ON
OFF
OFF
ON
ABS actuator motor
ON: Motor runs (ABS motor relay ON)
OFF: Motor stops (ABS motor relay OFF)
ABS MOTOR
G-SWITCH
UP (Increase):
KEEP (Hold):
DOWN (Decrease):
IN SOL
Ignition switch is ON or
engine is running.
Check G-switch circuit
OFF: G-switch OFF
ON: G-switch ON
Note: Active test will automatically stop ten seconds after the test starts. (LIMIT SIGNAL monitor shows
ON.)
BR-64
TROUBLE DIAGNOSES
Preliminary Check
Check brake fluid level in reservoir
tank.
-------------------------------------------------------------------------------------------------------------------------------------------------------Low fluid level may indicate brake pad
wear or leakage from brake line.
H
SBR451D
Check brake line for leakage.
NG
E
Repair.
OK
F
H
Check brake booster for operation and air
tightness. Refer to BR-14.
NG
E
Replace.
OK
F
H
Check brake pads, rotor and drums.
NG
SBR389C
E
Replace.
OK
H
Check brake fluid level in reservoir tank.
NG
E
Fill up brake fluid.
OK
H
SBR058C
Check warning lamp(s) or warning sound
activation.
When ignition switch is turned on, warning
lamp(s) turn(s) on.
NG
E
Check fuse, warning lamp
bulb and warning lamp circuit.
OK
H
Check warning lamp(s) for deactivation
after engine is started.
NG
E
Go to Self-diagnosis,
BR-59.
E
Go to Self-diagnosis,
BR-59.
OK
H
Drive vehicle at speeds over 30 km/h (19
MPH) for at least one minute.
H
SBR059C
Ensure warning lamp(s) remain(s) off
while driving.
OK
H
END
YBR266
BR-65
NG
TROUBLE DIAGNOSES
Ground Circuit Check
ABS CONTROL UNIT GROUND
I
Check resistance between ABS actuator and electric unit connector terminals and ground.
Resistance: approximately 0Ω
NBR321
BR-66
TROUBLE DIAGNOSES
Diagnostic Procedure 1 (Not self-diagnostic
item)
Warning lamp does not come on when ignition switch is
turned ON.
CHECK FUSE
Check 10A fuse 12 . For fuse layout, refer
to POWER SUPPLY ROUTING EL section.
NG
E
Replace fuse.
OK
H
CHECK ABS (and BRAKE) WARNING
LAMP(S) ACTIVATE
Disconnect ABS actuator and electric unit
connector.
Does the warning lamp(s) activate?
Yes
A
Eq
(Go to next page.)
No
H
YBR267
CHECK HARNESS FOR SHORT.
1. Disconnect ABS connector and electric
unit connector.
2. Check voltage between ABS actuator
and electric unit connector F29 (body
side) terminals q
21 , q
13 and ground.
Battery voltage should not exist.
NG
E
Repair harness or connector.
E
Replace harness or connector.
E
Replace bulb(s).
OK
H
Check voltage between combination connector LHD: F118 , RHD: M837 terminal q
28
and ground.
Battery Voltage should exist.
H
YBR268
OK
CHECK WARNING LAMP(S)
1. Turn ignition switch to “OFF” position.
2. Check ABS (and Brake) warning
lamp(s).
H OK
q
A
NBR322
YBR269
BR-67
NG
NG
TROUBLE DIAGNOSES
Diagnostic Procedure 1 (Not self-diagnostic
item) (Cont’d)
q
A
H
CHECK HARNESS FOR SHORT.
1. Disconnect combination meter connector LHD: F118 and F119 , or RHD: M837
and M838 .
2. Check continuity between ABS actuator
and electric unit connector F29 and
combination meter connector LHD:
F118 and F119 , or RHD: M837 and
M838 .
LHD:
F29
YBR270
E
Replace harness or connector(s).
E
Inspection end
LHD:
F119
F118
RHD:
RHD:
Continuity
M838
M837
Terminal
q
13
q
1
—
Yes
Terminal
q
21
—
q
44
Yes
H
NG
OK
Check combination meter
H
NG
CHECK HARNESS CONNECTOR.
Check ABS actuator and electric unit pin
terminals for damage or connection of
ABS actuator and electric unit harness
connector. Reconnect ABS actuator and
electric unit harness connector. Then
retest.
H
REPLACE.
Replace ABS actuator and electric unit.
BR-68
OK
TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Warning lamp stays
on when ignition switch is turned ON)
CHECK FUSE.
Check 10A fuse 19 . For fuse layout, refer
to POWER SUPPLY ROUTING in EL section.
NG
Eq
A
(Go to next page.)
OK
H
NG
CHECK WARNING LAMP.
B (Go to next page.)
Eq
1. Disconnect ABS actuator and electric
unit connector.
2. Connect suitable wire between ABS
actuator and electric unit harness connector F29 terminals q
13 , q
21 and ground.
Warning lamp should not activate.
H
YBR271
OK
CHECK HARNESS CONNECTOR.
Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector. Reconnect ABS actuator and
electric unit harness connector. Then
retest.
OK
E
Inspection end
NG
H
CHECK ABS MOTOR GROUND.
1. Turn ignition switch OFF.
2. Disconnect ABS actuator and electric
unit connector.
3. Check continuity between ABS actuator
and electric unit connector F29 (body
side) terminal q
16 and ground.
Continuity should exist.
NBR345
H
OK
REPLACE.
Replace ABS actuator and electric unit.
NBR326
BR-69
NG
E
Check the following.
I Harness connector F29
I Harness for open or short
between ABS actuator
and electric unit and
ground
If NG, repair harness or
connector.
TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Warning lamp stays
on when ignition switch is turned ON) (Cont’d)
q
A
H
REPLACE.
Replace fuse.
Does the fuse blow out when ignition
switch is turned ON?
No
E
Inspection end
Yes
H
NBR327
CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT
FOR SHORT.
1. Disconnect battery cable and ABS
actuator and electric unit connector
F29 .
2. Check continuity between ABS actuator
and electric unit connector F29 body
side terminal q
15 and ground.
Continuity should not exist.
H
NG
E
Check the following.
I Harness connector
F29
I Harness for open or short
between ABS actuator
and electric unit and fuse
If NG, repair harness or
connector.
OK
REPLACE.
Replace ABS actuator and electric unit.
q
B
H
NG Check the following.
CHECK ABS WARNING LAMP CONE
TROL CIRCUIT.
I Harness connectors
1. Disconnect combination meter connector
LHD: F118 and F119 , or
LHD: F118 and F119 , or RHD: M837 and
RHD: M837 and M838
M838 .
and F29
2. Check continuity between ABS actuator
I Harness for open or
and electric unit connector F29 (body
short between ABS
actuator and electric unit
side) terminal and combination meter
and combination meter
connector LHD: F118 and F119 , or
If NG, repair harness or
RHD: M837 and M838 .
connectors.
LHD:
F29
F118
RHD:
RHD:
Continuity
M838
M837
Terminal
q
13
q
1
—
Yes
Terminal
q
21
—
q
44
Yes
H
YBR270
LHD:
F119
OK
CHECK COMBINATION METER.
Check combination meter. Refer to WARNING LAMPS in EL section.
BR-70
TROUBLE DIAGNOSES
Diagnostic Procedure 3 (ABS actuator solenoid
valve and solenoid valve relay)
Malfunction code Nos. 41, 42, 45, 46, 55, 56, 63
CHECK FUSIBLE LINK.
Check 40A. For fusible link layout, refer to
POWER SUPPLY ROUTING in EL section.
H
H
(Go to next page.)
NG
B
Eq
(Go to next page.)
OK
CHECK CONNECTOR.
1. Disconnect ABS actuator and electric
unit connector. Check terminals for
damage or loose connection. Then
reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
NBR329
Eq
A
OK
CHECK FUSE.
Check 10A fuse 19 . For fuse layout, refer
to POWER SUPPLY ROUTING in EL section.
H
NG
No
E
Inspection end
Yes
CHECK ABS ACTUATOR AND ELECTRIC
UNIT GROUND CIRCUIT.
Refer to ABS ACTUATOR AND ELECTRIC
UNIT GROUND in Ground Circuit Check,
BR-66.
NG
E
Repair harness and connector.
OK
H
NBR330
CHECK SOLENOID VALVE RELAY
POWER SUPPLY CIRCUIT.
1. Disconnect ABS actuator and electric
unit connector.
2. Check voltage between ABS actuator
and electric unit connector F29 (body
side) terminal q
18 and ground.
Battery voltage should exist.
OK
H
REPLACE.
Replace ABS actuator and electric unit.
BR-71
NG
E
Check the following.
I Harness connector F29 ,
LHD: F68 and M784 , or
RHD: F79 and M744
I Harness for open or
short between ABS
actuator and electric unit
and fusible link
If NG, repair harness or
connector.
TROUBLE DIAGNOSES
Diagnostic Procedure 3 (ABS actuator solenoid
valve and solenoid valve relay) (Cont’d)
q
A
H
REPLACE.
Replace fusible link.
Does the fusible link blow out when
ignition switch is turned ON?
No
E
Inspection end
Yes
H
NBR331
CHECK SOLENOID VALVE RELAY
POWER SUPPLY CIRCUIT.
1. Disconnect battery cable and ABS
actuator and electric unit connector.
2. Check continuity between ABS actuator
and electric unit connector F29 (body
side) terminal q
18 and ground.
Continuity should not exist.
NG
E
Check the following
I Harness connector
F29 , LHD: F68 and
M784 , or RHD: F79 and
M744
I Harness for open or short
between ABS actuator
and electric unit and fusible link
If NG, repair harness or
connector.
OK
H
REPLACE.
Replace ABS actuator and electric unit.
q
B
H
REPLACE.
Replace fuse.
Does the fuse blow out when ignition
switch is turned ON?
No
H
END
Inspection end
BR-72
Yes
E
Check the following.
I Harness connector F29 ,
M822 , LHD: F66 and
M787 , or RHD: F76 :
, F136 :
, M743 :
and M829 :
I Harness for open or
short between ABS
actuator and electric unit
and fuse
If NG, repair harness or
connector.
TROUBLE DIAGNOSES
Diagnostic Procedure 4 (Wheel sensor or rotor)
Malfunction code No. 21, 22, 25, 26, 31, 32, 35, 36 or 18
YBR273
INSPECTION STARTS
1. Disconnect connectors from ABS actuator and electric unit and wheel sensor
of malfunction code No. Check terminals for damage or loose connections.
Then reconnect connectors.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
No
E
Inspection end
Yes
H
NBR332
CHECK WHEEL SENSOR ELECTRICAL.
1. Disconnect ABS actuator and electric
unit connector.
2. Check resistance between ABS actuator and electric unit connector F29
(body side) terminals.
Code No. 21 or 22 (Front RH wheel)
Terminals q
5 and q
4
Code No. 25 or 26 (Front LH wheel)
Terminals q
7 and q
6
Code No. 31 or 32 (Rear RH wheel)
Terminals q
2 and q
1
Code No. 35 or 36 (Rear LH wheel)
Terminals q
9 and q
8
Resistance: Front 0.9 - 1.1 kΩ
Rear 1.44 - 1.76 kΩ
OK
A
Eq
(Go to next page.)
NG
H
YBR274
CHECK WHEEL SENSOR.
Check each sensor for resistance.
Resistance: Front 0.9 - 1.1 kΩ
Rear 1.44 - 1.76 kΩ
NG
H
REPLACE.
Replace wheel sensor.
BR-73
OK
E
Check the following.
I Harness connectors
F29 , B57 , B58 , E15 :
, E211 :
and
F32
I Harness for open or
short between wheel
sensor connectors and
ABS actuator and electric unit
If NG, repair harness or
connectors.
TROUBLE DIAGNOSES
Diagnostic Procedure 4 (Wheel sensor or rotor)
(Cont’d)
q
A
Note
Note
H
CHECK TIRE.
Check for inflation pressure, wear and size
of each tire.
NG
E
Adjust tire pressure or
replace tire(s).
OK
Note
H
CHECK WHEEL BEARING
Check wheel bearing axial end play.
OK
Note
Note
H
CHECK SENSOR ROTOR.
Check sensor rotor for teeth damage.
NG
E
Replace sensor rotor.
OK
H
CHECK HARNESS CONNECTOR.
Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector.
Reconnect ABS actuator and electric unit
harness connector. Then retest.
Note: Wheel position should be distinguished by code numbers except code No. 18 (sensor rotor).
BR-74
TROUBLE DIAGNOSES
Diagnostic Procedure 5 (Motor Relay or motor)
Malfunction code No. 61
CHECK FUSIBLE LINK.
Check 40A. For fusible link layout, refer to
POWER SUPPLY ROUTING in EL section.
H
NG
A
Eq
(Go to next page.)
OK
CHECK CONNECTOR
1. Disconnect ABS actuator and electric
unit connector. Check terminals for damage or loose connection. Then reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
No
E
Inspection end
Yes
H
YBR275
CHECK MOTOR RELAY POWER SUPPLY CIRCUIT.
1. Disconnect ABS actuator and electric
unit connector.
2. Check voltage between ABS actuator
and electric unit connector F29 (body
side) terminal q
17 and ground.
Battery voltage should exist.
NG
E
OK
Check the following.
I Harness connector F29 ,
LHD: F68 and M784 , or
RHD: F79 and M744
I Harness for open or
short between ABS
actuator and electric unit
and fusible link.
If NG, repair harness or
connector.
H
CHECK ABS ACTUATOR AND ELECTRIC
UNIT GROUND.
Refer to ABS ACTUATOR AND ELECTRIC
UNIT GROUND in Ground Circuit Check,
BR-66.
NBR335
H
OK
REPLACE.
Replace ABS actuator and electric unit.
BR-75
NG
E
Repair harness and terminals.
TROUBLE DIAGNOSES
Diagnostic Procedure 5 (Motor Relay or motor)
(Cont’d)
q
A
H
REPLACE.
Replace fusible link.
Does the fusible link blow out when
ignition switch is turned ON?
No
E
Inspection end
Yes
NBR336
H
CHECK ABS ACTUATOR MOTOR
POWER SUPPLY CIRCUIT.
1. Disconnect battery cable and ABS
actuator and electric unit connector
F29 .
2. Check continuity between ABS actuator
and electric unit connector F29 (body
side) terminal q
17 and ground.
Continuity should not exist.
OK
H
CHECK HARNESS CONNECTOR.
Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector.
Reconnect ABS actuator and electric unit
harness connector. Then retest.
BR-76
NG
E
Check the following
I Harness connector F29 ,
LHD: F68 and M784 , or
RHD: F79 and M744
I Harness for open or
short between ABS
actuator and electric unit
and fusible link
If NG, repair harness or
connector.
TROUBLE DIAGNOSES
Diagnostic Procedure 7 (Low voltage)
Malfunction code No. 57
CHECK CONNECTOR.
1. Disconnect ABS actuator and electric
unit connector. Check terminals for
damage or loose connections. Then
reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
No
E
Inspection end
Yes
NBR337
H
CHECK ABS CONTROL UNIT POWER
SUPPLY CIRCUIT
1. Disconnect ABS actuator and electric
unit connector.
2. Check voltage between ABS actuator
and electric unit connector F29 terminal q
15 and ground.
Battery voltage should exist when
ignition switch is turned ON.
H
NBR338
A
Eq
(See below.)
OK
CHECK ABS CONTROL UNIT GROUND
Refer to ABS ACTUATOR AND ELECTRIC UNIT GROUND in Ground Circuit
Check, BR-66.
H
NG
NG
E
Repair harness and connector.
OK
CHECK HARNESS CONNECTOR.
Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector. Reconnect ABS actuator and
electric unit harness connector. Then
retest.
NG
E
Replace
Replace ABS actuator and
electric unit
q
A
H
CHECK FUSE.
Check 10A fuse 19 . For fuse layout, refer
to POWER SUPPLY ROUTING in EL section.
H
E
Replace fuse.
OK
CHECK ABS CONTROL UNIT POWER
SUPPLY CIRCUIT
Check continuity between fuse and ABS
actuator and electric unit connector F29
(body side) terminal q
15 .
OK
H
Check battery. Refer to BATTERY in EL
section.
BR-77
NG
NG
E
Check the following:
I Harness connector F29 ,
M822 , LHD: F66 and
M787 , or RHD: F76 :
, F136 :
, M743 :
and M829 :
I Harness for open or
short between ABS
actuator and electric unit
and fuse
If NG, repair harness or
connector.
TROUBLE DIAGNOSES
Diagnostic Procedure 8 (G sensor)
Malfunction code No. 17
CHECK G SENSOR POWER SUPPLY
CIRCUIT.
Check 10A fuse 19 . For fuse layout,
refer to POWER SUPPLY ROUTING in
EL section.
H
YBR276
E
Replace fuse.
OK
CHECK CONNECTOR.
1. Disconnect ABS actuator and electric
unit connector. Check terminals for
damage or loose connection. Then
reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
H
NG
No
E
Inspection end
Yes
CHECK G SENSOR.
Refer to G SENSOR in Electrical Components Inspection, BR-83
NG
E
Replace G sensor.
OK
YBR277
H
CHECK G SENSOR POWER SUPPLY
CIRCUIT.
1. Disconnect G sensor connectors.
2. Check voltage between G sensor connector terminals q
1 ( B59 ), q
3 ( B60 )
and ground.
Battery voltage should exist.
NG
E
OK
YBR278
Check the following.
I Harness connectors
B59 , B60 , LHD: B73 ,
RHD: B67 , LHD: F66 ,
RHD: F76 :
, RHD:
F136 :
, LHD: M787 ,
RHD: M743 :
, RHD:
M829 :
, LHD: F45 ,
RHD: F80 and M822
I Harness for open or
short between G sensor
and ABS actuator and
electric unit
If NG, repair harness or
connectors.
H
CHECK G SENSOR GROUND.
1. Disconnect ABS actuator and electric
unit connector and G sensor connectors.
2. Check continuity between ABS actuator
and electric unit connector F29 (body
side) terminals q
20 , q
10 and G sensor
connectors (body side) terminals q
2
( B59 ), q
4 ( B60 ).
Continuity should exist.
H
OK
CHECK HARNESS CONNECTOR.
Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector. Reconnect ABS actuator and
electric unit harness connector. Then
retest.
BR-78
NG
E
Check the following.
I Harness connectors
B59 , B60 , LHD: B73 ,
RHD: B67 , F29 , LHD:
F45 and RHD: F80
I Harness for open or
short between G sensor
and ABS actuator and
electric unit
If NG, repair harness or
connectors.
TROUBLE DIAGNOSES
Diagnostic Procedure 9 (Control unit)
Malfunctioning code No. 71
CHECK CONNECTOR.
1. Disconnect ABS actuator and electric
unit connector.
Check terminals for damage or loose
connections. Then reconnect connector.
2. Carry out self-diagnosis again.
Does warning lamp activate again?
NBR343
H
No
E
Inspection end
Yes
CHECK ABS ACTUATOR AND ELECTRIC UNIT POWER SUPPLY CIRCUIT
Check voltage. Refer to
in Diagnostic
Procedure 7, BR-77.
H
CHECK SELF-DIAGNOSTIC RESULTS
Does warning lamp indicate code No. 71
again?
H
No
INSPECTION
Inspect the system according to the code
No.
BR-79
Yes
E
Replace ABS actuator and
electric unit.
TROUBLE DIAGNOSES
Diagnostic Procedure 10 (Pedal vibration and
noise)
INSPECTION START
1. Apply brake.
2. Start engine.
3. Does the symptom appear only when
engine is started?
Yes
E
Carry out self-diagnosis.
Refer to BR-59.
E
Go to
in Diagnostic
Procedure 12, BR-81.
No
H
SAT797A
CHECK IF SYMPTOM APPEARS.
Does the symptom appear when electrical
equipment switches (such as headlamp)
are operated?
H
Yes
CHECK WHEEL SENSOR.
Check wheel sensor shield ground. For
location of shield ground, refer to wiring
diagram and “HARNESS LAYOUT” in EL
section.
H
No
NG
E
Repair wheel sensor.
OK
CHECK HARNESS CONNECTOR.
Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector.
Reconnect ABS actuator and electric unit
harness connector. Then retest.
Note: ABS may operate and cause vibration under any of the
following conditions.
Diagnostic Procedure 11 (Long stopping
distance)
CHECK ABS PERFORMANCE
Disconnect ABS actuator and electric unit
connector and check whether stopping
distance is still long.
H
No
E
in Diagnostic
Go to
Procedure 12, BR-81.
Yes
Perform Preliminary Check and air bleeding.
Note: Stopping distance may be larger than vehicles without
ABS when road condition is slippery.
BR-80
TROUBLE DIAGNOSES
Diagnostic Procedure 12 (Unexpected pedal
action)
CHECK BRAKE PEDAL STROKE.
Check brake pedal stroke. Is stroke excessively large?
H
SBR540A
Yes
E
Perform Preliminary
Check, refer to BR-65.
E
Perform Preliminary Check,
refer to BR-65.
E
Carry out self-diagnosis.
Refer to BR-59.
E
Repair.
No
CHECK BRAKE PERFORMANCE
Disconnect ABS actuator and electric unit
connector and check whether brake is
effective.
No
Yes
H
CHECK WARNING LAMP ACTIVATE.
Ensure warning lamp remains off while
driving.
H
YBR279
OK
CHECK WHEEL SENSOR.
1. Check wheel sensor connector for terminal damage or loose connection.
2. Perform wheel sensor mechanical
check.
Refer to Diagnostic Procedure 4,
BR-73.
H
NG
NG
OK
CHECK HARNESS CONNECTOR.
Check ABS actuator and electric unit pin
terminals for damage or the connection of
ABS actuator and electric unit harness
connector.
Reconnect ABS actuator and electric unit
harness connector. Then retest.
CAUTION: Drive at low speed and brake smoothly to prevent
rear wheels locking.
BR-81
TROUBLE DIAGNOSES
Diagnostic Procedure 13
SYMPTOM: ABS does not work.
Does the ABS warning lamp activate?
H
Go to
BR-81.
Yes
E
No
Carry out self-diagnosis.
Refer to BR-59.
in Diagnostic Procedure 12,
Note: ABS does not work when vehicle speed is under 10 km/h
(6 MPH).
Diagnostic Procedure 14
SYMPTOM: ABS works frequently.
CHECK WHEEL SENSOR.
1. Check wheel sensor connector for terminal damage or loose connections.
2. Perform wheel sensor mechanical
check.
Refer to Diagnostic Procedure 4,
BR-73.
H
Go to
BR-81.
OK
in Diagnostic Procedure 12,
BR-82
E
Repair.
OK
CHECK FRONT AXLES
Check front axles for excessive looseness. Refer to FA section (“Front Wheel
Bearing”, “ON-VEHICLE SERVICE”).
H
NG
NG
E
Repair.
TROUBLE DIAGNOSES
Electrical Components Inspection
WHEEL SENSOR
Check resistance for each sensor.
Resistance:
Front 0.9 - 1.1 kΩ
Rear 1.44 - 1.76 kΩ
YBR085
G SENSOR
Resistance between terminals q
3 and q
4
Continuity
Installed in vehicle
Approx. 1.5 kΩ
Yes
Tilted as shown in figure
Approx. 5.1 kΩ
No
Condition
YBR280
BR-83
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Wagon (LWB)
Hard Top (SWB)
Wagon (LWB)
Hard Top (SWB)
Applied model
Without ABS
With ABS
Front brake
LD28VA
Brake model
Cylinder bore diameter
43 (1.69)
mm (in)
Pad
mm (in)
length x width x thickness
Rotor outer
diameter x thickness
144.85 x 48.5 x 15.5
(5.70 x 1.90 x 0.61)
mm (in)
27.7 x 26.1
(10.91 x 1.02)
Drum brake
LT28
Brake model
Cylinder bore diameter
mm (in)
23.8 (0.94)
Lining
mm (in)
Length x width x thickness
Leading
22.0 (0.87)
20.6 (0.81)
111 x 55 x 8.95 (4.37 x 2.17 x 0.35)
Trailing
114 x 55 x 3.95 (4.49 x 2.17 x 0.16)
Drum inner
mm (in)
Diameter
280 (11.02)
Master cylinder
mm (in)
Cylinder bore diameter
25.4 (1.0)
Control valve
Valve model
Load Sensing Valve
—
2
Split point [kPa (bar, kg/cm , psi)] x
reducing ratio
Variable x 0.23
Variable x 0.15
—
Brake booster
Booster model
Lucas LSC 115 (8″ + 9″)
Diaphragm diameter
Primary: 203.2 (8)
Secondary: 228.6 (9)
mm (in)
Specified brake fluid
DOT 4
BR-84
SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment
DISC BRAKE
BRAKE PEDAL
Unit: mm (in)
Brake model
LD28VA
Pad wear limit
Minimum thickness
RHD
LHD
196 - 206
(7.7 - 8.1)
210 - 220
(8.3 - 8.7)
137.7 - 148.7
(5.42 - 5.85)
142.5 - 152.5
(5.61 - 6.0)
Free pedal height (H)
2.0 (0.079)
Full stroke (D)
Rotor repair limit
Minimum thickness
Unit: mm (in)
24.0 (0.94)
DRUM BRAKE
Clearance between pedal
stopper and threaded end of
stop lamp switch (C)
0.3 - 1.0 (0.012 - 0.039)
Pedal free play at clevis (A)
1 - 3 (0.039 - 0.118)
Unit: mm (in)
Lining wear limit
Minimum thickness
1.52 (0.06)
PARKING BRAKE
Control type
Drum repair limit
Item
Maximum inner diameter
280.5 (11.04)
Out-of-roundness
0.05 (0.0020)
or less
Number of notches
[under force of 196 N (20 kg, 44 lb)]
Number of notches
(when warning switch comes on)
BR-85
Center lever
9 - 10
1
NOTES